Terminating a cable assembly with connectorized pigtails

ABSTRACT

A multi-fiber cable assembly includes a pigtail segments spliced to a trunk segment using multiple mass fusion splices. The splices are disposed within an encapsulation at a common axial location. A flexible conduit extends from one end of the encapsulation to protect bare fibers of the trunk segment. A protective sheath extends from the opposite end of the encapsulation to protect the pigtail segments. The conduit and sheath are axially fixed to the encapsulation.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is being filed on Jul. 8, 2020 as a PCT InternationalPatent Application and claims the benefit of U.S. Patent ApplicationSer. No. 62/871,297, filed on Jul. 8, 2019, and claims the benefit ofU.S. Patent Application Ser. No. 62/986,179, filed on Mar. 6, 2020, thedisclosures of which are incorporated herein by reference in theirentireties.

BACKGROUND

In fiber optic networks, there is a push to increase density by usinghigher fiber count cables in data centers and elsewhere. Cables havinghundreds or even thousands of optical fibers each are being routed toequipment racks for connection. Ends of these cables are terminated atmultiple multi-fiber connectors (e.g., MPO plug connectors). Duringtermination, a cable jacket is removed to expose the optical fibers.Each optical fiber or small groups of fibers (e.g., fiber ribbons) maybe manually threaded through furcation tubes. Then, the ends of thethreaded fibers are connectorized, polished, and tested. Such a processis tedious, time-consuming, and labor intensive. Improvements aredesired.

SUMMARY

Certain aspects of the disclosure are directed to cable assemblies inwhich one or more pigtail segments are spliced to a fiber optic cable(e.g., to a trunk segment of a fiber optic cable) using multiple massfusion splices. The mass fusion splices are protected over asufficiently short axial distance to allow coiling of the cableassembly. For example, the mass fusion splices can all be located at acommon axial position along the cable.

The mass fusion splices are disposed within an encapsulation. In certainimplementations, the mass fusion splices are embedded within theencapsulation. In some examples, the encapsulation includes a housing(e.g., a plastic housing) at least partially filled with epoxy or otherfluid material. In other examples, the encapsulation includes anovermolded body.

In certain implementations, a flexible conduit (e.g., a corrugated tube)is fixedly coupled to one end of the encapsulation. In some examples,the conduit is mounted over the encapsulation. In other examples, theconduit is embedded within the encapsulation. At least bare fibers ofthe trunk segment are routed from a jacketed portion of the trunksegment to the splices. The bare fibers are sufficiently long to enablesplicing of the trunk segment fibers at a mass fusion splice machine.The flexible conduit protects the bare fibers after splicing. Theconduit is more flexible than the encapsulation.

In certain implementations, a protective sheath is fixedly coupled tothe opposite end of the encapsulation. For example, the protectivesheath may be embedded within the encapsulation. Portions of the pigtailsegments are routed through the protective sheath to the splices. Thebare fibers are sufficiently long to enable splicing of the pigtailsegment fibers at a mass fusion splice machine. The protective sheath ismore flexible than the encapsulation.

In certain implementations, the protective sheath includes a spiral wrapmember disposed about a bundle of cables; and a securement member thatholds an end of the spiral wrap member outside a circumferentialboundary of the cable bundle. The bundle can include optical fibers,electrical connectors, and/or other media segments. In an example, thesecurement member holds the end of the spiral wrap at a fixed radialposition relative to the bundle. In an example, the securement memberholds the end of the spiral wrap at a fixed axial position relative tothe bundle. In an example, the securement member holds the end of thespiral wrap at a fixed circumferential position relative to the bundle.

In some implementations, the securement member includes a conduit. Inother implementations, the securement member includes a tie member. Incertain implementations, a respective securement member can be utilizedat opposite ends of the spiral wrap member to secure both ends.

A variety of additional inventive aspects will be set forth in thedescription that follows. The inventive aspects can relate to individualfeatures and to combinations of features. It is to be understood thatboth the forgoing general description and the following detaileddescription are exemplary and explanatory only and are not restrictiveof the broad inventive concepts upon which the embodiments disclosedherein are based.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the description, illustrate several aspects of the presentdisclosure. A brief description of the drawings is as follows:

FIG. 1 is a side elevational view of a first example cable assemblyincluding multiple mass fusion splices disposed within an encapsulation;

FIG. 2 is a longitudinal cross-sectional view of the first cableassembly of FIG. 1;

FIG. 3 is a perspective view of the first cable assembly of FIG. 1 withthe components exploded from each other for ease in viewing;

FIG. 4 is a perspective view of an example first housing piece of ahousing arrangement of the first cable assembly of FIG. 1;

FIG. 5 is an interior plan view of the first housing piece of FIG. 4;

FIG. 6 is an exterior plan view of the first housing piece of FIG. 4;

FIG. 7 is a perspective view of an example second housing piece of thehousing arrangement of the first cable assembly of FIG. 1;

FIG. 8 is an exterior plan view of the second housing piece of FIG. 7;

FIG. 9 is an interior plan view of the second housing piece of FIG. 7;

FIG. 10 is a perspective view of an example third housing piece of thehousing arrangement of the first cable assembly of FIG. 1;

FIG. 11 is another perspective view of the third housing piece of FIG.10;

FIG. 12 is a perspective view of a first example ring clip suitable foruse with the first cable assembly of FIG. 1;

FIG. 13 is a perspective view of a second example ring clip suitable foruse with the first cable assembly of FIG. 1;

FIG. 14 is a side elevational view of a second example cable assemblyincluding multiple mass fusion splices disposed within an encapsulation;

FIG. 15 is a longitudinal cross-sectional view of the second cableassembly of FIG. 14;

FIG. 16 is a perspective view of the second cable assembly of FIG. 14with the components exploded from each other for ease in viewing;

FIG. 17 is a perspective view of an example plug body for an exampleplug suitable for use with the second cable assembly of FIG. 14;

FIG. 18 is a perspective view of a third example ring clip suitable foruse with the second cable assembly of FIG. 14;

FIG. 19 is a perspective view of an example gland arrangement with afirst gland body shown exploded from a second gland body;

FIG. 20 is a perspective view of the gland arrangement of FIG. 19 in anassembled state;

FIG. 21 is a perspective view of an example securement arrangement forone or both ends of a spiral wrap type protective sheath for a bundle ofmedia segments (e.g., optical fibers), the securement arrangementincluding a conduit;

FIG. 22 is a perspective view of an example spiral wrap member suitablefor forming a protective sheath around a bundle of media segments;

FIG. 23 is a perspective view of an example conduit suitable for use insecuring an end of the spiral wrap member of FIG. 22;

FIG. 24 is an end view of the conduit of FIG. 23;

FIG. 25 is a cross-sectional view of the conduit of FIG. 24 taken alongthe 25-25 line;

FIG. 26 is a cross-sectional view of the conduit of FIG. 24 taken alongthe 26-26 line;

FIG. 27 is an enlarged view of a portion of the securement arrangementof FIG. 21;

FIG. 28 is a transverse cross-sectional view of the securementarrangement of FIG. 27 taken along the 28-28 line;

FIG. 29 is a perspective view of another example securement arrangementfor both ends of a spiral wrap type protective sheath, the securementarrangement including a respective conduit for each end;

FIG. 30 is a perspective view of another example securement arrangementfor one or both ends of a spiral wrap type protective sheath, thesecurement arrangement including a tie member;

FIG. 31 is a perspective view of the example tie member of FIG. 30 in anunwrapped configuration;

FIG. 32 is a perspective view of the tie member of FIG. 31 in a wrappedconfiguration;

FIG. 33 is a perspective view of an example cable assembly includingpigtail segments spliced to opposite ends of a trunk segment, the cableassembly also including first and second fanout housings orencapsulations to protect the optical splices;

FIG. 34 is a perspective view of a portion of the cable assembly of FIG.33 where only one of the fanout housings or encapsulations is shown;

FIG. 35 is a perspective view of the fanout housing or encapsulation ofFIG. 34 shown with the components exploded from each other for ease inviewing;

FIG. 36 is a cross-sectional view of the portion of the cable assemblyof FIG. 34 with the conduit shown slid away from the fanout housing orencapsulation to expose the protective sheath extending between thetrunk cable jacket and the fanout housing or encapsulation;

FIG. 37 is a top plan view of the fanout housing or encapsulation ofFIG. 34 shown with a third housing piece removed to expose thesolidified material through apertures in the fanout housing orencapsulation;

FIG. 38 is a cross-sectional view of a portion of the fanout housing orencapsulation of FIG. 34;

FIG. 39 is a perspective view of one end of another example cableassembly including multiple groups of pigtail segments spliced to atrunk segment, the cable assembly also including a fanout housing orencapsulation protecting the optical splices; and

FIG. 40 is a perspective view of the cable assembly of FIG. 39 shownwith components exploded from each other for ease in viewing.

DETAILED DESCRIPTION

Reference will now be made in detail to exemplary aspects of the presentdisclosure that are illustrated in the accompanying drawings. Whereverpossible, the same reference numbers will be used throughout thedrawings to refer to the same or like parts.

Referring to FIGS. 1, 2, 14, 15, and 33-35, a multi-fiber cable assembly100, 200, 400, 500 extends axially along a longitudinal axis L between afirst end 101, 201, 401, 501 and a second end 102, 202, 402, 502. Thecable assembly 100, 200, 400, 500 includes a trunk segment 110, 410, 510and a plurality of pigtail segments 120, 420, 520. The trunk segment110, 410, 510 includes a plurality of optical fibers 112, 412, 512surrounded by a jacket 114, 414, 514. Each pigtail segment 120, 420, 520includes a plurality of optical fibers 122, 422, 522 terminated at acommon multi-fiber plug connector 126, 426, 526. The optical fibers 122,422, 522 of each pigtail segment 120, 420, 520 are spliced tocorresponding ones of the optical fibers 112, 412, 512 of the trunksegment 110, 410, 510 at respective mass fusion splices 130, 430, 530.

In some implementations, the pigtail segments 120, 420, 520 are coupled(e.g., spliced) to only one side of the trunk segment 110, 410, 510. Inother implementations, the pigtail segments 120, 420, 520 are coupled(e.g., spliced) to opposite ends of the trunk segment 110, 410, 510(e.g., see FIG. 33).

In some implementations, the pigtail segments 120, 420, 520 are splicedto the trunk segment 110, 410, 510 using a laminated mass fusion splice.Examples of laminated mass fusion splices are described in more detailin U.S. Provisional Appl. No. 62/836,294, filed Apr. 19, 2019, andtitled “Flexible Splice,” the disclosure of which is hereby incorporatedherein by reference in its entirety. In other implementations, thepigtail segments 120, 420, 520 are spliced to the trunk segment 110,410, 510 using other types of mass fusion splices.

The mass fusion splices 130, 430, 530 are disposed within anencapsulation 140, 440, 540. The encapsulation 140, 440, 540 can bereferred to as a fanout housing. The encapsulation 140, 440, 540 extendsbetween a first axial end 140 a, 440 a, 540 a and a second axial end 140b, 440 b, 540 b. In an example, the encapsulation 140, 440, 540 iselongate between the first and second axial ends 140 a, 140 b, 440 a,440 b, 540 a, 540 b. In certain implementations, the splices 130, 430,530 are held at a fixed position within the encapsulation 140, 440, 540.In some implementations, the encapsulation 140, 440, 540 includes ahollow body filled with epoxy or other material M (e.g., see FIGS.1-13). In other implementations, the encapsulation 140 includes anovermolded body fully surrounding the splices 130 (e.g., see FIGS.14-18). In still other implementations, the splices are disposed withina hollow cavity within the encapsulation 140, 440, 540. Theencapsulation 140, 440, 540 is designed to be assembled around thesplices 130, 430, 530 as will be described in more detail herein.

A conduit 150, 450 extends between a jacketed portion of the trunksegment 110, 410, 510 and the second axial end 140 b, 440 b, 540 b ofthe encapsulation 140, 440, 540. The trunk segment fibers 112, 412, 512are routed through the conduit 150, 450. In certain examples, theconduit 150, 450 includes a corrugated tube. The conduit 150, 450 ismore flexible than the encapsulation 140, 540, thereby allowing thecable assembly 100, 200, 400, 500 to be wound on a spool or mandrel. Incertain implementations, the conduit 150, 450 extends between a firstend 152, 452 that couples to the encapsulation 140, 440, 540 and asecond end 154 that couples to the jacketed portion of the trunk segment110, 410, 510. The conduit 150, 450 is sized to hold all of the opticalfibers 112, 412, 512 of the trunk segment 110, 410, 510. In certainimplementations, the conduit 150, 450 defines an axial slit extendingbetween the first and second ends 152, 154 to facilitate laterallymounting the conduit 150, 450, 550 over the trunk segment fibers 112,412, 512.

A protective sheath 160, 460, 560 extends from the first axial end 140a, 440 a, 540 a of the encapsulation 140, 440, 540 towards themulti-fiber connectors 126, 426, 526. The protective sheath 160, 460,560 is axially fixed to the encapsulation 140, 440, 540. In certainimplementations, the sheath 160, 460, 560 is embedded within theencapsulation 140, 440, 540. In some implementations, the sheath 160,460 is sized to hold all of the optical fibers 122, 422 of the pigtailsegments 120, 420. In other implementations, each sheath 560 is sized tohold the optical fibers 522 of a subset of the pigtail segments 520.Accordingly, a cable assembly 500 can include multiple protectionsheaths 560 extending from the first axial end 540 a of theencapsulation 540 (e.g., see FIG. 39). In certain implementations, eachprotection sheath 560 can be routed to a different chassis or section ofa chassis of a communications panel (e.g., a termination panel, a splicepanel, etc.).

Each sheath 160, 460, 560 is more flexible than the encapsulation 140,44, 540 thereby allowing the cable assembly 100, 200, 400, 500 to bewound on a spool or mandrel. In some implementations, the sheath 160,460, 560 provides bend radius protection to the optical fibers 122, 422,522 held therein. In other implementations, the sheath 160, 460, 560holds the respective fibers 122, 422, 522 together in a group formanipulation as a unit. In some implementations, the sheath 160, 460,560 includes a spiral wrap sheath (see FIGS. 3, 35, and 40) that can bewrapped around some or all of the pigtail segments 120, 420, 520 afterthe pigtail segments 120, 420, 520 are spliced to the trunk segment 110,410, 510. In other implementations, the sheath 160, 460, 560 includes amesh sleeve defining an axial slit through which some or all of thepigtail segments 120, 420, 520 can be inserted into the mesh sleeve 160,460, 560 after being spliced to the trunk segment 110, 410, 510.

The cable assembly 100, 200, 400, 500 is coilable about a spool ormandrel. In certain implementations, the encapsulation 140, 440, 540 hasa transverse cross-dimension that defines the maximum transversecross-dimension of the cable assembly 100, 200, 400, 500. In someimplementations, the encapsulation 140, 440, 540 has a maximumtransverse cross-dimension of no more than 4 inches. In certainimplementations, the encapsulation 140, 440, 540 has a maximumtransverse cross-dimension of no more than 3 inches. In certainimplementations, the encapsulation 140, 440, 540 has a maximumtransverse cross-dimension of no more than 2 inches.

The cable assembly 100, 200, 400, 500 includes at least twenty-fourtrunk segment fibers 112, 412, 512. In certain implementations, thecable assembly 100, 200, 400, 500 includes at least seventy-two trunksegment fibers 112, 412, 512. In certain implementations, the cableassembly 100, 200, 400, 500 includes at least one hundred forty-fourtrunk segment fibers 112, 412, 512. In certain implementations, thecable assembly 100, 200, 400, 500 includes at least two hundredeighty-eight trunk segment fibers 112, 412, 512. In certainimplementations, the cable assembly 100, 200, 400, 500 includes at least576 trunk segment fibers 112, 412, 512. In certain implementations, thecable assembly 100, 200, 400, 500 includes at least 864 trunk segmentfibers 112, 412, 512. In certain implementations, the cable assembly100, 200, 400, 500 includes at least 1,728 trunk segment fibers 112,412, 512. In certain implementations, the cable assembly 100, 200, 400,500 includes at least 3,456 trunk segment fibers 112, 412, 512. Incertain implementations, the cable assembly 100, 200, 400, 500 includesat least 6,912 trunk segment fibers 112, 412, 512.

For ease in viewing, only a single pigtail segment 120 is shown in FIGS.1-32. It will be understood, however, that the cable assembly 100, 200,400, 500 includes at least two pigtail segments 120, 420, 520. Incertain implementations, the cable assembly 100, 200, 400, 500 includesat least six pigtail segments 120, 420, 520. In certain implementations,the cable assembly 100, 200, 400, 500 includes at least twelve pigtailsegments 120, 420, 520. In certain implementations, the cable assembly100, 200, 400, 500 includes at least twenty-four pigtail segments 120,420, 520. In certain implementations, the cable assembly 100, 200, 400,500 includes at least forty-eight pigtail segments 120, 420, 520. Incertain implementations, the cable assembly 100, 200, 400, 500 includesat least seventy-two pigtail segments 120, 420, 520. In certainimplementations, the cable assembly 100, 200, 400, 500 includes at least144 pigtail segments 120, 420, 520. In certain implementations, thecable assembly 100, 200, 400, 500 includes at least 288 pigtail segments120, 420, 520.

FIGS. 1-13 illustrate the components of a first example cable assembly100. FIGS. 14-18 illustrate the components of a second example cableassembly 200. FIGS. 33-38 illustrate the components of a third examplecable assembly 400. FIGS. 39-40 illustrate the components of a fourthexample cable assembly 500.

In the first example cable assembly 100, the encapsulation 140 includesa housing arrangement 141 defining a cavity 145 in which the mass fusionsplices 130 can be disposed. In certain examples, the cavity 145 canthen be filled with a fluid material M (e.g., epoxy or other adhesive,molding material, etc.) that solidifies within the cavity 145. Thehousing arrangement 141 includes at least a first housing piece 142 anda second housing piece 144 that cooperate to define the cavity 145.Because the housing arrangement 141 is formed from at least two pieces,the housing arrangement 141 can be easily assembled around the massfusion splices 130.

In certain implementations, the housing arrangement 141 also includes athird piece 146. For example, the second housing piece 144 may define anaperture 148 providing access to the cavity 145 from an exterior of thehousing arrangement 141. The material M may be inserted into the cavity145 through the aperture 148. The third housing piece 146 may couple tothe second housing piece 144 to close the aperture 148. In certainimplementations, the third housing piece 146 latches or otherwisesecures to the second housing piece 144. In certain implementations, thethird housing piece 146 is installed before or while the fluid material(e.g., epoxy) M is solidifying (e.g., curing). In such implementations,the material can hold the third housing piece 146 to the second housingpiece 144.

FIGS. 4-6 illustrate an example first housing piece 142 and FIGS. 7-9illustrate an example second housing piece 144. In certainimplementations, the first and second housing pieces 142, 144 aresubstantially identical except that the second housing piece 144 alsodefines the aperture 148. Each housing piece 142, 144 has a body 300extending between a first end 301 and a second end 309. The bodies 300include an attachment arrangement to hold the bodies 300 together. Incertain examples, at least one of the bodies 300 includes latches 308and at least the other of the bodies 300 includes catches 310 configuredto receive the latches 308. In the example shown, both bodies 300include both latches 308 and catches 310.

Each body 300 defines a first region 302, a second region 304, and athird region 306. The first, second, and third regions 302, 304, 306cooperate to define a respective channel extending axially through thebody 300. The channels at the first regions 302 cooperate to define thecavity 145 in which the splices 130 may be disposed. The first regions302 also cooperate to define a pocket 312 at the first end 301 of thecavity 145. A wall structure 313 at least partially separates the pocket312 from the remainder of the cavity 145. The second region 304 has asmaller transverse cross-dimension than the first region 302. The thirdregion 306 has a smaller transverse cross-dimension than the secondregion 304. The exterior of the second and/or third regions 304, 306 mayinclude ridges 316 or other texturing.

FIGS. 10 and 11 illustrate an example third housing piece 146 configuredto couple to the second housing piece 144. The third housing piece 146includes a body 320 extending between a first end 321 and a second end329. The body 320 defines a closing surface 322 defining a periphery326. In certain implementations, the closing surface 322 is sized sothat the periphery 326 fits within the aperture 148 of the secondhousing piece 144. Accordingly, the third housing piece 146 may fitwithin a profile defined by the first and second housing pieces 142,144.

In certain implementations, an attachment structure couples the thirdhousing piece 146 to the second housing piece 144. In certain examples,the attachment structure includes latches 324 and catches 328 (FIG. 7).In the example shown, the latches 324 are provided by the third housingpiece 146 and the catches 328 are provided by the second housing piece144. In other examples, however, both housing pieces 144, 146 caninclude latches 324 and catches 328. In the example shown, the latches324 are recessed inwardly from the periphery 326 to permit the closingsurface 322 to extend across the aperture 148 of the second housingpiece 144.

As shown in FIGS. 2 and 3, in certain implementations, the trunk segment110 is coupled to the housing arrangement 141 directly or through theconduit 150. For example, the fibers 112 of the trunk segment 110 extendfrom the splices 130, through part of the cavity 145 of the housingarrangement 141, and out of the second axial end 140 b of the housingarrangement 141. Accordingly, at least a portion of the fibers 112 aredisposed within the solidified material M within the housing arrangement141. In some implementations, strength members of the trunk segment 110secure to the housing arrangement 141. In other implementations,strength members of the trunk segment 110 secure to the conduit 150. Forexample, strength members of the trunk segment 110 can be routed throughthe conduit 150 with the fibers 112 and into the housing arrangement 141to be encapsulated in the solidified material M with the fibers 112 andsplices 130.

The conduit 150 is coupled to the third region 306 of the housingarrangement 141. For example, the third region 306 of the housingarrangement 141 may be inserted into the conduit 150 (e.g., see FIG. 2).Ribs 316 at the third region 306 may aid in holding the conduit 150 tothe housing arrangement 141. In certain implementations, the conduit 150may be further secured to the housing arrangement 141 using a retentionsleeve (e.g., a heat-shrink tube) 156. The retention sleeve 156 extendsover the second region 304 of the housing arrangement 141 and over aportion of the conduit 150 at the first end 152 of the conduit 150.

The retention sleeve 156 is threaded onto the trunk segment 110 beforesplicing the pigtail segments 120 to the trunk segment 110. In certainexamples, the retention sleeve 156 carries adhesive at an inner surfaceto bond to the housing arrangement 141 and/or conduit 150. In certainexamples, the retention sleeve 156 shrinks against the housingarrangement 141 and/or conduit 150 (e.g., the sleeve 156 is thermallyresponsive, the sleeve 156 is resilient, etc.). In certainimplementations, the second region 304 of the housing arrangement 141defines ribs 316 or other texturing to aid in holding the retentionsleeve 156 at the second region 304.

In certain implementations, a second retention sleeve 158 may secure thesecond end 154 of the conduit 150 to the trunk segment 110. Theretention sleeve 158 is threaded onto the trunk segment 110 beforesplicing the pigtail segments 120 to the trunk segment 110. Theretention sleeve 158 extends over the second end 154 of the conduit 150and over a portion (e.g., a jacketed portion) of the trunk segment 110.In certain examples, the retention sleeve 158 carries adhesive at aninner surface to bond to the conduit 150 and/or trunk segment 110. Incertain examples, the retention sleeve 158 shrinks against the conduit150 and/or trunk segment 110 (e.g., the sleeve 158 is thermallyresponsive, the sleeve 158 is resilient, etc.). In certainimplementations, the conduit 150 spaces the retention sleeves 156, 158from each other.

In some implementations, strength members of the trunk segment 110 aresecured to the second end 154 of the conduit 150. In otherimplementations, strength members of the trunk segment 110 are securedto the first end 152 of the conduit 150. In other implementations,strength members of the trunk segment 110 are secured to the housingarrangement 141. For example, the strength members may be routed throughthe conduit 150 and sandwiched between the third region 306 of thehousing arrangement 141 and the first end 152 of the conduit 150.

In certain implementations, the fibers 112 of the trunk segment 110 havea combined transverse cross-sectional area sufficient to inhibit fluidmaterial M injected into the cavity 145 from flowing into the conduit150. For example, the fibers 112 function as a plug for the fluidmaterial M. In certain implementations, the fibers 112 plug the materialM from flowing into the third region 306 of the housing arrangement 141.In certain implementations, the fibers 112 plug the material M fromflowing into the second region 304 of the housing arrangement 141. Incertain implementations, tape can be wrapped around the fibers 112 atthe second region 304 and/or at the third region 306 to help plug thematerial M. In certain implementations, strength members of the trunksegment 110 can be routed through the conduit 150 with the fibers 112and into the housing arrangement 141 to be encapsulated in the materialM with the fibers 112 and splices 130.

Still referring to FIGS. 2 and 3, the pigtail segments 120 are securedto the encapsulation 140 using the material M. For example, the pigtailsegments 120 extend from the splices 130, through part of the cavity 145of the housing arrangement 141, and out of the first axial end 140 a ofthe housing arrangement 141. The protective sheath 160 disposed aroundthe pigtail segments 120 also extends into the housing arrangement 141through the first end 140 a. In certain implementations, a ring clip 170or other plug is disposed within the housing arrangement 141 at thefirst end 140 a to inhibit material M from exiting the housingarrangement 141 at the first end 140 a. For example, the ring clip 170may seat within the pocket 312 (see FIG. 2).

FIGS. 12 and 13 illustrate example ring clips 170A, 170B. Each ring clip170A, 170B includes a body 172 defining a through-passage 174. The body172 also defines an axial slit 176 providing radial access to thethrough-passage 174 from an exterior of the body 172. The body 172 issufficiently resilient to enable flexing of the body 172 to open orwiden the slit 176. Accordingly, the pigtail segments 120 can belaterally loaded into the ring clip 170A, 170B via the slit 176.Laterally loading the pigtail segments 120 allows the ring clip 170A,170B to hold more pigtail segments 120 than it otherwise would had theconnectorized ends 126 of the pigtail segments needed to be threadedthrough the through-passage 174.

The ring clip 170A shown in FIG. 12 is suitable for use with a spiralwrap sheath 160 as shown in FIG. 3. Pigtail segments 120 are loaded intothe ring clip 170A and the ring clip 170A is disposed in the pocket 312within the housing cavity 145. The pocket 312 axially retains the ringclip 170A at the first end 140 a of the housing arrangement 141. Thering clip 170A is sized to fit around the spiral wrap sheath 160 (seeFIG. 2). In certain implementations, the ring clip 170A plugs the firstend 140 a of the housing arrangement 141 to inhibit fluid material Mfrom leaking or otherwise exiting the housing cavity 145 through thefirst end 140 a. For ease in viewing, FIG. 2 shows only one pigtailsegment 120 extending through the sheath 160. In use, a plurality ofpigtail segments 120 would extend through the sheath 160 sufficient toblock flow of the material M out of the housing 141 through the sheath160.

The ring clip 170B shown in FIG. 13 is suitable for use with a meshsleeve type sheath 160. The mesh sleeve and the ring clip 170B bothdefine respective axial slits through which the pigtail segments 120 areloaded. In certain implementations, the ring clip 170B also includesteeth 178 or other catch features to engage the mesh sleeve (e.g., toprotrude through holes defined by the mesh). In some examples, the teeth178 are disposed at an exterior of the body 172 and the ring clip 170Bis mounted inside of the mesh sleeve 160. Accordingly, when the ringclip 170B is disposed in the pocket 312, the mesh sleeve is radiallysandwiched between the ring clip 170B and the housing arrangement 141.In certain examples, the ring clip 170B axially holds the mesh sleeve160 at the first end 140 a of the housing arrangement 141. In certainexamples, the ring clip 170B plugs the first end 140 a against flow ofmaterial M out of the housing cavity 145.

As shown in FIGS. 14-16, the encapsulation of the cable assembly 200 caninclude an overmolded body 210 extending between a first axial end 210 aand a second axial end 210 b. The overmolded body 210 is formed byplacing a mold (e.g., a two-piece mold) around the splices 130, thefirst end 152 of the conduit 150, and the second end 164 of theprotective sheath 160. A molding material is injected into the mold andsolidifies around the splices 130, conduit first end 152, and sheathsecond end 164. The mold is then removed from the solidified moldingmaterial, leaving the overmolded body 210.

The second cable assembly 200 differs from the cable assembly 100 inthat the conduit 150 is coupled to the encapsulation 140 by beingembedded within the overmolded body 210 instead of being mounted to anexterior of a housing arrangement 141. Overmolding the body 210 of theencapsulation 140 allows for a greater variety in the size and shape ofthe encapsulation. Instead of fitting the encapsulated components withina set housing size or within one of a series of set housing sizes, themold can be set up to accommodate the number of splices 130, trunkfibers 112, and pigtail segments 120 for each given cable assembly.

As with cable assembly 100, in certain implementations, a retentionsleeve 256 can be used to further axially retain the conduit 150 at theencapsulation 140. In certain examples, the retention sleeve 256 extendsat least partially over the encapsulation 140 and at least partiallyover the trunk segment 110. In the example shown, the retention sleeve256 extends fully over the overmolded body 210. In other examples, theretention sleeve 256 may extend over a majority, but less than all, ofthe overmolded body 210. In still other examples, the retention sleeve256 extends over only the second end 214 of the overmolded body 210.

Because the first end 152 of the conduit 150 is embedded within theovermold body 210, a plug 220 is disposed at the first end 152 of theconduit 150 to inhibit the overmold material from flowing into theconduit 150. The plug 220 is sized to fill in a gap between the trunksegment fibers 112 and the first end 152 of the conduit 150. In certainimplementations, the plug 220 is designed to be laterally mounted aroundthe trunk fibers 112 (e.g., after the trunk fibers 112 are spliced tothe pigtail segments 120). In certain examples, the plug 220 includesfirst and second bodies 222 that cooperate to define a through-passage224. The through-passage 224 is sized so that the trunk segment fibers112 fill the through-passage 224 sufficient to inhibit the overmoldmaterial from entering the conduit 150 through the through-passage 224.

The plug 220 includes a first section 226 that extends into the conduit150 from the first end 152. The plug 220 also includes a second section228 disposed external of the conduit 150. The second section 228inhibits axial movement of the plug 220 fully into the conduit 150, evenwhen the cable assembly 200 is held vertically. The second section 228may be contoured (e.g., funnel-shaped). In certain examples, the plugbodies 222 do not attach to each other. Rather, the bodies 222 are heldtogether by the conduit 150.

During the overmolding process, the cable assembly 200 is heldvertically with the conduit 150 being disposed beneath the protectivesheath 160. Accordingly, the ring clip 170 is not needed as a plug.Instead, the ring clip 170 fits over the protective sheath 160 to holdthe protective sheath 160 at a fixed position within the mold toproperly position the second end 164 of the sheath 160 within theovermolded body 210. An example ring clip 170C suitable for use with theovermolded body 210 is shown in FIG. 18. The ring clip 170A stillincludes a body 172, through-passage 174, and slit 176. However,centering tabs 179 extend outwardly from an exterior of the body 172. Incertain examples, the centering tabs 179 are sized to contact interiorsurfaces of the mold to hold the ring clip 179C and contents thereof ata fixed position within the mold.

In the third and fourth example cable assemblies 400, 500, theencapsulation 440, 540 includes a housing arrangement 441, 541 defininga cavity 445, 545 in which the mass fusion splices 430, 530 can bedisposed. In certain examples, the cavity 445, 545 can then be filledwith fluid material M (e.g., epoxy or other adhesive, molding material,etc.). The housing arrangement 441, 541 defines mounting structure bywhich the housing arrangement 441, 541 can be secured to a surface(e.g., a panel, a cable, or another such housing arrangement 441, 541).In certain implementations, the mounting structure includes one or moreaperture 443, 543 extending through the housing arrangement 441, 541separate from the cavity 445, 545. In some examples, a cable tie orother wrap/winding structure can extend through the apertures 443, 543to hold the housing arrangement 441, 541 to the surface. In otherexamples, the apertures 443, 543 may be sized and shaped to receivefasteners (e.g., bolts, screws, etc.) for holding the housingarrangement 441, 541 to the surface. In some examples, the apertures443, 543 are sized and configured to match bolt holes on atelecommunications rack when the housing arrangement 441, 541 extendsvertically between the first and second ends 440 a, 440 b, 540 a, 540 b.In other examples, the apertures 443, 543 are sized and configured tomatch the bolt holes when the housing arrangement 441, 541 extendshorizontally. In other implementations, the mounting structure mayinclude latch arms, pegs, or other mounting members.

In certain implementations, the housing arrangement 441, 541 includes atleast a first housing piece 442, 542 and a second housing piece 444, 544that cooperate to define the cavity 445, 545. Because the housingarrangement 441, 541 is formed from at least two pieces, the housingarrangement 441, 541 can be easily assembled around the mass fusionsplices 430, 530. In certain implementations, the housing arrangement441, 541 also includes a third piece 446, 546. For example, the secondhousing piece 444, 544 may define one or more apertures 448, 548providing access to the cavity 445, 545 from an exterior of the housingarrangement 441, 541. In the examples depicted in FIGS. 35 and 40, thesecond housing piece 444, 544 defines a first aperture 448 a, 548 a anda second aperture 448 b, 548 b. The fluid material M may be insertedinto the cavity 445, 545 through the aperture(s) 448, 548.

The third housing piece 446, 546 may couple to the second housing piece444, 544 to close the aperture(s) 448, 548. In some examples, the thirdhousing piece 446, 546 covers multiple apertures 448 a, 448 b, 548 a,548 b. In other examples, each aperture 448 a, 448 b, 548 a, 548 b has arespective third housing piece 446, 546. In certain implementations, thethird housing piece 446, 546 latches or otherwise secures to the secondhousing piece 444, 544. In the example depicted in FIGS. 35 and 40, thesecond housing 441, 541 includes a bridge 447, 547 supporting a peg orother protruding member 449, 549 that friction-fits, latches, orotherwise secures within an aperture defined by the third housing piece446, 546. In certain examples, the bridge 447, 547 reinforces the secondhousing piece 444, 544 and/or the third housing piece 446, 546 while thefluid material M is inserted and solidifying. In certainimplementations, the third housing piece 446, 546 is installed before orwhile the material M is solidifying (e.g., the epoxy is curing). In suchimplementations, the solidified material M can hold the third housingpiece 446, 546 to the second housing piece 444, 544. In certainexamples, the third housing piece 446, 546 may defines vent holes. Incertain examples, the material M is visible through the holes whensufficient material M has been injected into the housing arrangement441, 541.

In some implementations, the first and second housing pieces 442, 444,542, 544 are substantially identical except that the second housingpiece 444, 544 also defines the aperture(s) 448, 548. In otherimplementations, the first and second housing pieces are identical andthe apertures 448, 548 are initially closed with a punch-out or otherremovable piece. Each housing piece 442, 444, 542, 544 include anattachment arrangement to hold the housing piece 442, 444, 542, 544together. In certain examples, at least one of the housing pieces 442,444, 542, 544 includes latches 308 and at least the other of the housingpiece 442, 444, 542, 544 includes catches 310 configured to receive thelatches 308. In the example shown, both housing pieces 442, 444, 542,544 include both latches 308 and catches 310. In the example shown inFIG. 35, the latches 308 are disposed at one side of each housing piece442, 444, 542, 544 and the catches 310 are disposed at the other side ofthe housing piece 442, 444, 542, 544.

Each housing piece 442, 444, 542, 544 defines a first region 302, asecond region 304, and a third region 306. The first, second, and thirdregions 302, 304, 306 cooperate to define a respective channel extendingaxially through each housing piece 442, 444, 542, 544. The channels atthe first regions 302 cooperate to define the cavity 445, 545 in whichthe splices 430, 530 may be disposed. The first regions 302 alsocooperate to define one or more pockets 312 at the first end of thecavity 445, 545. One or more wall structures at least partially separatethe pockets 312 from the remainder of the cavity 445, 545. The housingpieces 442, 444, 542, 544 define a pocket 312 for each pigtailprotective sheath 460, 560 that extends from the first end 440 a, 540 aof the encapsulation 440, 540.

The second region 304 has a smaller transverse cross-dimension than thefirst region 302. The second region 304 defines a port 315 through whichfluid material M may enter the cavity 445 of the housing arrangement441. In particular, the fluid material M may enter the second region 304of the cavity 445, 545. In certain examples, the port 315 may functionas a vent to allow air to escape from the second region 304 while fluidmaterial M is being injected into the cavity 445, 545 through theapertures 448, 548. In certain implementations, a protective sheath460′, 560′ is disposed about the trunk cable fibers 412, 512 within theconduit 450, 550. The projective sheath 460′, 560′ inhibits pinching ofthe trunk fibers 412, 512 while the trunk fibers 412, 512 are disposedwithin the housing arrangement 441, 541. In certain examples, theprotective sheath 460′, 560′ about the trunk cable fibers 412, 512 issubstantially the same as the protective sheath 460, 560 disposed aboutthe pigtail segments 420, 520.

A first end of the protective sheath 460′, 560′ extends into theencapsulation 440, 540 through the second end 440 b, 540 b. The firstend of the protective sheath 460′, 560′ is disposed within the secondregion 304. Fluid material M entering the cavity 445, 545 through theinjection port 315 surrounds the first end of the protective sheath460′, 560′ to axially secure the protective sheath 460′m 560′ to theencapsulation 440, 540 (e.g., see FIGS. 36 and 38). In certain examples,the protective sheath 460′, 560′ is sized to correspond to an interiorof the third region 306 to inhibit the fluid material M from leaking outbetween an exterior of the protective sheath 460′, 560′ and theencapsulation 440, 540. In certain examples, the trunk cable fibers 412,512 fill or substantially fill the interior of the protective sheath460′, 560′ to inhibit the fluid material M from leaking out of theencapsulation 440, 540 from an interior of the protective sheath 460′,560′.

The third region 306 has a smaller transverse cross-dimension than thesecond region 304. The exterior of the third region 306 may includeridges or other texturing. The texturing may aid in holding the conduit450 to the housing arrangement 441. In certain implementations, theconduit 450 may be further secured to the housing arrangement 441 usinga retention sleeve (e.g., a heat-shrink tube) 456. The retention sleeve456 extends over at least the first region 306 of the housingarrangement 441 and over a portion of the conduit 450 at the first end452 of the conduit 450. In certain examples, the retention sleeve 456extends over the second region 304 of the housing arrangement 141,thereby covering the injection port 315.

In use, the cable assembly 100, 200, 400, 500 is manufactured quicklyand easily by pre-preparing the pigtail segments 120, 420, 520 and thensplicing the pre-prepared pigtail segments 120, 420, 520 to the trunksegment 110, 410, 510. Because the pigtail segments 120, 420, 520 arepre-prepared, the labor and/or resource intensive steps of polishing andtesting the connectorization of the pigtail segments can be done aheadof time (e.g., at a dedicated location). Accordingly, the technician(s)manufacturing the cable assembly 100, 200, 400, 500 need not spend timetesting the connectorization of the individual fibers. Further, thetechnician need not spend time threading trunk segment fibers 112, 412,512 through furcation tubes or otherwise upjacketing the trunk segmentfibers 112.

Rather, the cable assembly 100, 200, 400, 500 is manufactured bystripping an end of the trunk segment 110, 410, 510 to expose barefibers 112, 412, 512 that are sufficiently long to reach a splicemachine (e.g., a mass fusion splicer). The retention sleeves 156, 256,158, 456, 458 are threaded onto the trunk segment 110, 410, 510 prior tosplicing. In certain examples, the conduit 150, 450, 550 also isthreaded onto the trunk segment 110, 410, 510 prior to splicing.

The pigtail segments 120, 420, 520 are prepared (e.g., pre-prepared at adifferent location) to have bare fiber segments 122, 422, 522 ofsufficient length to splice to the bare fibers 112, 412, 512 of thetrunk segment 110, 410, 510. In certain implementations, the trunkfibers 112, 412, 512 and pigtail fibers 122, 422, 522 are sufficientlylong to enable re-splicing of the optical fibers 112, 122, 412, 422,512, 522 if needed. In certain implementations, the trunk fibers 112,412, 512 and pigtail fibers 122, 422, 522 are sufficiently long toenable re-splicing of the optical fibers 112, 122, 412, 422, 512, 522multiple times.

In certain implementations, the connectorized ends 126, 426, 526 of thepigtail segments 120, 420, 520 are plugged into testing equipment duringthe splicing step. Accordingly, a technician can immediately determinewhether the splice was successful. If the splice was not successful,then the technician can attempt to re-splice the fibers 112, 122, 412,422, 512, 522 as needed while still at the splicing machine.

Once the pigtail segments 120, 420, 520 are spliced to the trunk segment110, 410, 510, the encapsulation 140, 440, 540 is installed around thesplices 130, 430, 530. In certain implementations, the splices 130, 430,530 are all disposed at a common axial position within the encapsulation140, 440, 540 along the longitudinal axis of the cable assembly 100,200, 400, 500. In certain implementations, the splices 130, 430, 530 arearranged so that the splices 130, 430, 530 stack together along an axisthat is transverse to the longitudinal axis of the cable assembly 100,200, 400, 500. In certain examples, the splices 130, 430, 530 can bedisposed in multiple stacks at the common axial position. In certainimplementations, the splices 130, 430, 530 are arranged so that eachsplice overlaps with at least some of the other splices 130, 430, 530.In certain implementations, the splices 130, 430, 530 are arranged sothat each splice overlaps with at least a majority of the other splices130, 430, 530. In certain implementations, the splices 130, 430, 530 arearranged so that no splice 130, 430, 530 is offset from the othersplices 130, 430, 530 by more than a length of the splice 130, 430, 530.In certain implementations, the splices 130, 430, 530 are arranged sothat no splice 130, 430, 530 is offset from the other splices 130, 430,530 by more than half a length of the splice 130, 430, 530.

The conduit 150, 450, 550 is positioned adjacent the splices 130, 430,530. In some implementations, the conduit 150, 450, 550 defines an axialslit and is laterally installed over the trunk segment 110, 410, 510. Inother implementations, the conduit 150, 450, 550 is pre-threaded overthe trunk segment 110, 410, 510 prior to splicing the pigtail segments120, 420, 520 to the trunk segment 110, 410, 510. The protective sheath160, 460, 560 is laterally installed over the pigtail segments 120, 420,520. The first end 152, 452 of the conduit 150, 450, 550 and the secondend 164 of the protective sheath 160, 460, 560 are appropriatelypositioned relative to the encapsulation 140, 440, 540. Fluid material(e.g., epoxy or other adhesive, molding material, etc.) M is applied toform the encapsulation 140, 440, 540 with the second end 164 of theprotective sheath 160, 460, 560 embedded therein.

In some implementations, the encapsulation 140, 440, 540 is installed byplacing the splices 130, 430, 530 within a cavity 145, 445, 545 of ahousing arrangement 141, 441, 541. For example, first and second housingpieces 142, 144, 442, 444, 542, 544 can be disposed around the splices130, 430, 530 to enclose the splices 130, 430, 530. The first end 152 ofthe conduit 150, 450, 550 may be mounted over a third region 306 of thehousing arrangement 141, 441, 541. The second end 164 of the protectivesheath 160, 460, 560 is inserted within a ring clip 170 and insertedwithin the housing arrangement 141, 441, 541. The ring clip 170 ispositioned within a pocket 312 within the housing arrangement 141, 441,541. The fluid material is injected into the cavity 145, 445, 545through an aperture(s) 148, 448, 548 in the housing arrangement 141,441, 541. A third housing piece 146, 446, 546 is installed at theaperture(s) 148, 448, 548 to close the cavity 145, 445, 545. The fluidmaterial solidifies as it cures. The solidified material and the housingarrangement 141, 441, 541 cooperate to form the encapsulation 140, 440,540. In certain examples, a first end of the protective sheath 460′,560′

In other implementations, the encapsulation 140, 440, 540 in installedby orienting the cable assembly 200 vertically so that the splices 130,430, 530 are disposed above the trunk segment 110, 410, 510 and at leastportions of the pigtail segments 120, 420, 520 are disposed above thesplices 130, 430, 530. A plug 220 is installed at the first end 152 ofthe conduit 150, 450, 550. A ring clip 170 is installed about the firstend 164 of the protective sheath 160, 460, 560. A mold is assembledaround the splices 130, 430, 530, the first end 152 of the conduit 150,450, 550, and the second end 164 of the protective sheath 160, 460, 560.Molding material is injected into the mold to surround the first end 152of the conduit 150, 450, 550 and the second end 164 of the protectivesheath 160, 460, 560. In some implementations, the mold material alsosurround the splices 130, 430, 530. The molding material solidifies asit cures to form an overmolded body 210, which defines the encapsulation140, 440, 540.

In still other implementations, the housing arrangement 141, 441, 541may remain devoid of encapsulating material and still form a fanouthousing around the splices 130, 430, 530, the first end of the conduit150, 450, 550, and the second end of the protective sheath 160, 460,560.

The first retention sleeve 156, 256, 456 is slid over the conduit 150,450, 550 towards the encapsulation 140, 440, 540. A first portion of thefirst retention sleeve 156, 256, 456 is slid over at least a portion ofthe encapsulation 140, 440, 540. In some examples, the first portion ofthe first retention sleeve 156, 456 is slid over the second and thirdregions 304, 306 of the housing arrangement 141, 441, 541. In otherexamples, the first portion of the first retention sleeve 256 is slidover the overmolded body 210 (e.g., over an entirety of the overmoldedbody). A second portion of the first retention sleeve 156, 256, 456remains over the conduit 150, 450, 550. In certain examples, the firstretention sleeve 156, 256, 456 carries adhesive at an internal surfaceto bond to the encapsulation 140, 440, 540 and/or to the conduit 150,450, 550. In some examples, the first retention sleeve 156, 256, 456 isthermally reactive and shrinks when heated. In other examples, the firstretention sleeve 156, 256, 456 is resilient and shrinks when a spacer isremoved.

The second retention sleeve 158, 458 is slid over the trunk segment 110,410 towards the conduit 150, 450, 550. A first portion of the secondretention sleeve 158, 458 is slid over the second end 154 of the conduit150, 450, 550. A second portion of the second retention sleeve 158, 458remains over a jacketed portion of the trunk segment 110, 410, 510. Incertain examples, the second retention sleeve 158, 458 carries adhesiveat an internal surface to bond to the encapsulation 140, 440, 540 and/orto the conduit 150, 450, 550. In some examples, the second retentionsleeve 158, 458 is thermally reactive and shrinks when heated. In otherexamples, the second retention sleeve 158, 458 is resilient and shrinkswhen a spacer is removed.

As discussed above, in certain implementations, the protective sheath160, 460, 560 includes a mesh sleeve. The second end 164 of the meshsleeve 160, 460, 560 is retained at the encapsulation 140, 440, 540. Incertain implementations, the first end of the mesh sleeve 160, 460, 560can be retained at a gland arrangement configured to be plugged into apanel or other structure closer to the connection point for the pigtailconnectors 126, 426, 526. The gland arrangement includes latching tabsor other attachment features that allow the gland arrangement to beattached to the panel or other structure.

FIGS. 19 and 20 illustrate one example gland arrangement 250 including afirst gland body 252 and a second gland body 254 that couple together.Each gland body 252, 254 defines a through-passage 256, 258,respectively. When the gland bodies 252, 254 are assembled together, thethrough-passages 256, 258 align to provide a through-passage through thegland arrangement 250. In certain examples, the gland bodies 252, 254latch or otherwise releasably couple together. In certainimplementations, the first end of the mesh sleeve 160 can be sandwiched(e.g., radially sandwiched) between the two gland bodies 252, 254.

In certain implementations, each of the gland bodies 252, 254 defines anaxial slit 260, 262, respectively, that provides access between anexterior of each body 252, 254 and the respective through-passage 256,258. The axial slit 260, 262 allows the pigtail segments 120 to belaterally loaded into the gland bodies 252, 254. Accordingly, thepigtail segments 120 can be loaded into the gland bodies 252, 254without threading the connectorized ends 126 through thethrough-passages 256, 258. Further, the pigtail segments 120 can beloaded into the gland bodies 252, 254 at any desired time during themanufacture of the cable assembly 100, even after the pigtail segments120 are spliced to the trunk segment 110.

As shown in FIG. 20, the axial slits 260, 262 are disposed on the glandbodies 252, 254 so that the axial slits 260, 262 are circumferentiallyoffset from each other when the gland bodies 252, 254 are assembled.Rotationally offsetting the slits 260, 262 inhibits the pigtail segments120 from being pulled out of the gland arrangement 250 after the glandarrangement 250 is assembled.

Referring now to FIGS. 21-32, the protective sheath 160, 460, 560includes a spiral-wrap member 161 that extends in a spiral configurationabout a longitudinal axis A (FIG. 22) extending from a first end 162 toa second end 164. The spiral wrap member 161 has a thickness T extendingradially away from the longitudinal axis A and a width W extending alongthe longitudinal axis A when the wrap member 161 is disposed in thespiral configuration. In some implementations, the thickness T isconstant along the width W. In other implementations, the thickness T islarger towards a center of the width W. In certain examples, the wrapmember 161 is contoured along the width W so that the thickness T at thecenter of the width W is larger than the thickness T at the oppositesides of the width W.

The spiral-wrap member 161 defines an internal passage 165 along thelongitudinal axis A. The passage 165 is sized so that one or moreoptical fibers 162 can extend therethrough. In certain examples, abundle of optical fibers 162 extends through the passage 165 (e.g., seeFIG. 21). In some implementations, the second end 164 of the spiral-wrapmember is secured to the encapsulation (see FIGS. 2 and 15). In otherimplementations, the second end 164 may be unattached to theencapsulation 140.

The first end 162 of the spiral wrap member 161 tends to curve towardsthe fiber bundle extending through the passage 165. In certain cases,the first end 162 may extend partially into the bundle (e.g., betweenadjacent fibers 162). In other cases, the first end 162 may radiallycompress fibers 162 or create a pinch point if wrapped around a largefiber bundle. To inhibit such behavior, a securement member is used tomanage the first end 162. For example, the securement member holds thefirst end 162 of the spiral wrap member 161 at a first fixed positionexternal of the fiber bundle. In various examples, the securement memberholds the second end 162 at a fixed radial position, a fixed axialposition, and/or a fixed circumferential position relative to the fiberbundle.

FIGS. 21-29 show one example securement member implemented as a conduitmember 270 disposed at the first end 162 of the spiral wrap member 161.The conduit member 270 holds the first end 162 of the spiral wrap member161 in the first fixed position (e.g., fixed radial position, fixedaxial position, and/or fixed circumferential position) relative to thefiber bundle. In certain implementations, the conduit 270 holds thefirst end 162 of the spiral wrap member 161 in a fixed position (e.g.,fixed radial position, fixed axial position, and/or fixedcircumferential position) relative to an intermediate section 166 of thespiral wrap member 161 that is disposed between the first and secondends 162, 164 of the spiral wrap member 161.

The conduit member 270 includes a body defining a passage 275 extendingbetween opposite first and second openings 271, 273 leading to thepassage 275. The conduit passage 275 is sized to receive the first end162 of the spiral wrap member 161 layered over an intermediate section166 of the spiral wrap member 161. The passage 275 is sized to retainthe first end 162 of the spiral wrap member 161 via a friction fit. Incertain implementations, the passage 275 has a generally rectangularcross-sectional area. The passage 275 is formed from opposing side walls277 and opposing end walls 279 that each extend along the passage 275between the first and second openings 271, 273.

In certain implementations, the passage 275 is sufficiently long toencourage enough contact between the first end 162 and the intermediatesection 166 to produce a frictional resistance to movement therebetween.In certain implementations, the sidewalls 277 of the passage 275 aresufficiently short so that the end walls 279 press the first end 162against the intermediate section 166 in the direction of thickness T ofthe spiral wrap member 161, thereby enhancing friction between the firstend 162 and the intermediate section 166. In certain implementations,the end walls 279 taper laterally inwardly towards a center of thepassage 275 (e.g., see FIG. 26) to compress the second end 162 and theintermediate section 166 towards each other within the conduit 270,thereby enhancing friction between the first end 162 and theintermediate section 166.

An exterior of the conduit 270 is shaped to inhibit damage to the fibers162. In certain implementations, the exterior of the conduit 270 iscontoured to avoid sharp edges. For example, the exterior corners 280 ofthe conduit 270 may be rounded. In certain implementations, the firstand second openings 271, 273 may be rectangular. In certainimplementations, the conduit 270 is formed from plastic. In certainimplementations, the spiral-wrap member 161 is formed from plastic.

In certain implementations, a second conduit member 270 can be disposedat the second end 164 of the spiral wrap member 161 to retain the secondend 164 in a fixed position (e.g., fixed radial position, fixed axialposition, and/or fixed circumferential position) relative to the fiberbundle B. The second conduit member 270 can be identical to the firstconduit member 270. The second conduit member 270 can be utilized if thesecond end 164 of the spiral wrap member 161 is not otherwise secured atthe encapsulation 140. Accordingly, the first and second conduit members270 can be used in conjunction with the spiral wrap member 161 to securea bundle of fibers at a location spaced from the encapsulation 140. Theconduits 170 and spiral wrap member 161 can even be used to hold abundle of non-spliced fibers together.

FIGS. 30-32 show another example securement member implemented as a tiemember 282 disposed at the first end 162 of the spiral wrap member 161.The tie member 282 holds the first end 162 of the spiral wrap member 161and fastens around the fiber bundle B to hold the first end 162 externalof a circumferential boundary of the fiber bundle B. In certainexamples, the tie member 282 holds the first end at a fixed radialposition relative to the fiber bundle B. In certain examples, the tiemember 282 holds the first end at a fixed circumferential positionrelative to the fiber bundle B. In certain examples, the tie member 282holds the first end at a fixed axial position relative to the fiberbundle B.

As shown in FIG. 31, the tie member 282 extends along a first axis Ebetween a head end 284 and an opposite tail end 286. The tie member 282includes a stem 294 extending from the head end 284 to the tail end 294along the first axis E. At least a portion of the stem 294 includes aseries of teeth 296. The tie member 282 has a length 51 extending alongthe first axis E, a width S2 extending transverse to the length 51, anda thickness S3 extending transverse to both the length 51 and the widthS2. The length 51 is greater than the width S2 and the width S2 isgreater than the thickness S3.

The tie member 282 include first and second receptacles 290, 292,respectively, at the head end 284. Each of the first and secondreceptacles 290, 292 defines a respective passage therethrough. Thefirst receptacle 290 is sized to receive the tail end 286. The stem 294is configured to enable the stem 294 to pass through the firstreceptacle 290 in a first direction. The teeth 296 engage catch surfacesat the first receptacle 290 to inhibit movement of the stem 294 in anopposite second direction through the first receptacle 292. Tighteningthe stem 294 within the first receptacle 290 secures the tie member 282about the fiber bundle B.

In certain implementations, the passage of the second receptacle 292 islarger than the passage of the first receptacle 290. The secondreceptacle 292 is sized to receive at least the first end 162 of thespiral wrap member 161. In certain implementations, the secondreceptacle 292 is sized to enable the first end 162 to be inserted intothe passage, but to inhibit axial movement of the stem 294 through thepassage of the second receptacle 292. For example, the passage of thesecond receptacle 292 may about match the thickness S3 of the stem 294of the tie member 282. In some implementations, the second receptacle292 has a constant transverse cross-sectional area throughout thepassage. In other implementations, the transverse cross-sectional areaof the passage is reduced towards a center of the passage to aid inretaining the first end 162 of the spiral wrap member 161 within thesecond receptacle 292.

The second receptacle 292 is laterally offset from the first axis Ealong a second axis F that is transverse to the first axis E. Thepassage of the second receptacle 292 is parallel to, but laterallyoffset along the width S2 from, the first axis E of the tie member 282.In certain implementations, the first and second receptacles 290, 292are aligned along the axis F. Accordingly, securing the tie member 282around an exterior boundary of the fiber bundle B maintains the firstend 162 extending through the second receptacle 292 external of thefiber bundle boundary. In certain implementations, the passages definedby the first and second receptacles 290, 292 extend parallel to eachother. In some implementations, the first receptacle 290 is aligned withthe tail end 286 along the first axis E. In other implementations, thefirst receptacle 290 is laterally offset from the first axis E along thesecond axis F in an opposite direction from the second receptacle 292.

In certain implementations, a second tie member 282 can be disposed atthe second end 164 of the spiral wrap member 161 to retain the secondend 164 in a fixed position (e.g., fixed radial position, fixed axialposition, and/or fixed circumferential position) relative to the fiberbundle B. The second tie member 282 can be identical to the first tiemember 282. The second tie member 282 can be utilized if the second end164 of the spiral wrap member 161 is not otherwise secured at theencapsulation 140. Accordingly, the first and second tie members 282 canbe used in conjunction with the spiral wrap member 161 to secure abundle B of fibers at a location spaced from the encapsulation 140. Thetie members 282 and spiral wrap member 161 can even be used to hold abundle B of non-spliced fibers together.

Having described the preferred aspects and implementations of thepresent disclosure, modifications and equivalents of the disclosedconcepts may readily occur to one skilled in the art. However, it isintended that such modifications and equivalents be included within thescope of the claims which are appended hereto.

1.-68. (canceled)
 69. A multi-fiber cable assembly extending axiallyalong a longitudinal axis, the multi-fiber cable comprising: a trunksegment including a plurality of optical fibers surrounded by a jacket,the optical fibers extending between opposite first and second ends; aplurality of pigtail segments optically coupled to the trunk segment,each pigtail segment including a plurality of optical fibers extendingfrom first ends to second ends, the first ends of the optical fibers ofeach pigtail segment being terminated at a respective multi-fiberconnector, the second ends of the optical fibers of each pigtail segmentbeing spliced at a respective mass fusion splice to the first ends of atleast some of the optical fibers of the trunk segment; a fanout housingdisposed around the mass fusion splices, the fanout housing extendingbetween a first axial end and a second axial end, the mass fusionsplices aligning with each other within the fanout housing along an axisthat is transverse to the longitudinal axis; a conduit disposed about aportion of the trunk segment, the conduit extending along thelongitudinal axis between a first end and a second end, the first end ofthe conduit extending into the second axial end of the fanout housingand being axially fixed within an interior of the fanout housing; and aprotective sheath extending from the first axial end of the fanouthousing, the protective sheath being disposed about at least some of thepigtail segments, the protective sheath extending along the longitudinalaxis between a first end and a second end, the second end of theprotective sheath being axially fixed within the fanout housing.
 70. Themulti-fiber cable assembly of claim 69, wherein a solidified materialencapsulates the mass fusion splices, the first end of the conduit, andthe second end of the protective sheath.
 71. The multi-fiber cableassembly of claim 70, wherein the fanout housing is overmolded about themass fusion splices to form the solidified material.
 72. The multi-fibercable assembly of claim 70, wherein the solidified material is disposedwithin the fanout housing.
 73. The multi-fiber cable assembly of claim72, wherein the fanout housing defines at least one aperture throughwhich fluid material can be injected into the fanout housing, the fluidmaterial being configured to solidify within the fanout housing.
 74. Themulti-fiber cable assembly of claim 73, wherein the fanout housingdefines a plurality of apertures.
 75. The multi-fiber cable assembly ofclaim 74, wherein a single cover piece of the fanout housing coversmultiple ones of the apertures.
 76. The multi-fiber cable assembly ofclaim 69, wherein the protective sheath is one of a plurality ofprotective sheaths extending from the first axial end of the fanouthousing, each of the protective sheaths disposed about a subset of thepigtail segments.
 77. The multi-fiber cable assembly of claim 69,wherein the protective sheath is the only protective sheath extendingfrom the first axial end of the fanout housing, the protective sheathsurrounding all of the pigtail segments.
 78. The multi-fiber cableassembly of claim 69, wherein the fanout housing includes multiplehousing pieces.
 79. The multi-fiber cable assembly of claim 69, whereinthe protective sheath includes a spiral wrap.
 80. The multi-fiber cableassembly of claim 79, wherein the second end of the protective sheath isheld by a securement member at a fixed radial position, a fixed axialposition, and a fixed circumferential position relative to the opticalfibers of the pigtail segment.
 81. The multi-fiber cable assembly ofclaim 69, wherein a second protective sheath is disposed about theoptical fibers of at least a portion of the trunk segment.
 82. Themulti-fiber cable assembly of claim 69, wherein the mass fusion splicesare disposed in one or more stacks within the fanout housing at a commonposition along the longitudinal axis.
 83. The multi-fiber cable assemblyof claim 82, wherein the optical fibers of the trunk segment includes864 fibers.
 84. The multi-fiber cable assembly of claim 82, wherein theoptical fibers of the trunk segment includes 1,728 fibers.
 85. A cablemanagement arrangement comprising: a spiral wrap member extendingbetween opposite first and second ends, the spiral wrap member having aspiral configuration about a longitudinal axis extending between thefirst and second ends, the spiral wrap member having a thicknessextending radially away from the longitudinal axis; and a conduit memberdefining a passage extending between opposite first and second openings,the passage being sized to receive two overlapping layers of the spiralwrap member therethrough such that the two overlapping layers arefriction fit within the passage.
 86. The cable management arrangement ofclaim 85, wherein the conduit member is a first conduit member disposedat the first end of the spiral wrap member; and wherein a second conduitmember is disposed at the second end of the spiral wrap member, thesecond conduit member defining a second passage extending betweenopposite respective first and second openings, the second passage beingsized to receive two respective overlapping layers of the spiral wrapmember therethrough such that the two respective overlapping layers arefriction fit within the second passage.
 87. A cable managementarrangement for managing a bundle of cables, the cable managementarrangement comprising: a tie member extending along an axis betweenopposite first and second ends, the tie member having a length extendingalong the axis, a width transverse to the length, and a thicknesstransverse to both the length and the width, the length being greaterthan the width and the width being greater than the thickness, the tiemember including a first receptacle and a second receptacle disposed atthe first end, each of the first and second receptacles defining arespective passage therethrough, at least the second receptacle beingparallel to, but laterally offset along the width from the axis of thetie member, the first end of the tie member being configured to bereceived within the passage of the first receptacle.
 88. The cablemanagement arrangement of claim 87, wherein the passage of the firstreceptacle is aligned with the axis.